Thermoplastic polyolefin compositions useful for aldehyde abatement

ABSTRACT

A composition comprises: (A) a polypropylene polymer; (B) a polyolefin elastomer; (C) a compound having the formula (I) defined herein; and (D) an additive component. And an article made from the composition.

BACKGROUND

The present disclosure relates to thermoplastic polyolefin compositions useful for aldehyde abatement.

Automobile interior parts are typically made of thermoplastic polyolefin (TPO) compositions, such as TPO compositions containing polyolefin elastomers (POE). Increasing pressures and consumer concerns regarding car interior air quality have led to government regulations that limit the concentration of volatile organic compounds (VOCs), such as aldehydes, permissible in automobile interior parts. For example, certain regulations have been recently implemented which limit the concentration of aldehydes in automobile interior parts to less than 0.10 mg/m³ formaldehyde, less than 0.20 mg/m³ acetaldehyde, and less than 0.05 mg/m³ acrolein.

Consequently, a need exists for a thermoplastic polyolefin composition useful for aldehyde abatement. A need also exists for a thermoplastic polyolefin composition that significantly reduces aldehyde concentrations while maintaining the balance of mechanical properties important for automobile interior parts, such as sufficient toughness and stiffness.

SUMMARY OF THE INVENTION

In certain embodiments, the present disclosure relates to a thermoplastic polyolefin composition comprising:

(A) a polypropylene polymer;

(B) an elastomer component; and

(C) a compound having the formula (I):

-   -   wherein R1, R2, and R3 are each independently H, a linear or         branched alkyl group having 1 to 10 carbon atoms, a hydroxyl         group, a phenyl group, a halogen, —CO2CH3, or —CN.

Optionally, in certain embodiments, the composition of the present disclosure may further comprise (D) an additive component and/or (E) a compatibilizer.

In certain embodiments, the present disclosure relates to a thermoplastic polyolefin composition comprising:

(A) from 50 wt % to 99.99 wt % of a polypropylene polymer;

(B) from 0 wt % to 35 wt % of an elastomer component;

(C) from 0.01 wt % to 20 wt % of a compound having the formula (I):

-   -   wherein R1, R2, and R3 are each independently H, a linear or         branched alkyl group having 1 to 10 carbon atoms, a hydroxyl         group, a phenyl group, a halogen, —CO2CH3, or —CN;

(D) from 0 wt % to 49.99 wt % of an additive component; and

(E) from 0 wt % to 10 wt % of a compatibilizer.

In certain embodiments, the present disclosure relates to an article made from a thermoplastic polyolefin composition comprising:

(A) a polypropylene polymer;

(B) an elastomer component; and

(C) a compound having the formula (I):

-   -   wherein R1, R2, and R3 are each independently H, a linear or         branched alkyl group having 1 to 10 carbon atoms, a hydroxyl         group, a phenyl group, a halogen, —CO2CH3, or —CN.

Optionally, in certain embodiments, an article made from the thermoplastic polyolefin composition of the present disclosure may further comprise (D) an additive component and/or (E) a compatibilizer.

DETAILED DESCRIPTION Definitions

For purposes of United States patent practice, the contents of any referenced patent, patent application or publication are incorporated by reference in their entirety (or its equivalent U.S. version is so incorporated by reference) especially with respect to the disclosure of definitions (to the extent not inconsistent with any definitions specifically provided in this disclosure) and general knowledge in the art.

The numerical ranges disclosed herein include all values from, and including, the lower and upper value, as well as decimal values. For ranges containing explicit values (e.g., 1 to 7), any subrange between any two explicit values is included (e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).

Unless stated to the contrary, implicit from the context, or customary in the art, all parts and percents are based on weight and all test methods are current as of the filing date of this disclosure.

An “elastomer” is a polymer that experiences large reversible deformations under relatively low stress. Elastomers can either be thermoplastic or thermoset. “Thermoplastic elastomers” are elastomers having thermoplastic properties. That is, thermoplastic elastomers are optionally molded or otherwise shaped and reprocessed at temperatures above their melting or softening point. The polyolefin elastomers suitable for use herein are thermoplastic elastomers.

An “ethylene-based polymer,” “ethylene polymer,” or like terms mean a polymer that contains equal to or greater than 50 wt %, or a majority amount of, polymerized ethylene monomer (based on the total weight of the polymer) and, optionally, may contain at least one comonomer.

An “ethylene/α-olefin polymer” or “ethylene/alpha-olefin polymer” is a polymer that contains equal to or greater than 50 wt %, or a majority amount of, polymerized ethylene, based on the weight of the polymer, and one or more alpha-olefin comonomers.

A “homopolymer” is a polymer comprising repeating units derived from a single monomer type, but does not exclude residual amounts of other components used in preparing the homopolymer, such as chain transfer agents.

“Olefin polymer,” “olefinic polymer,” “olefinic interpolymer,” “polyolefin” and like terms refer to a polymer derived from simple olefins. A “polyolefin” contains equal to or greater than 50 wt %, or a majority amount of, polymerized olefin monomer (based on the total weight of the polymer) and, optionally, may contain at least one comonomer. Nonlimiting examples of α-olefin monomer include C₂, or C₃ to C₄, or C₆, or C₈, or C₁₀, or C₁₂, or C₁₆, or C₁₈, or C₂₀ α-olefins, such as ethylene, propylene, 1-butene, 1-hexene, 4-methyl-1-pentene, and 1-octene. Representative polyolefins include polyethylene, polypropylene, polybutene, polyisoprene, and their various interpolymers.

A “polymer” is a compound prepared by polymerizing monomers, whether of the same or a different type, that in polymerized form provide the multiple and/or repeating “units” or “mer units” that make up a polymer. “Polymer” includes homopolymers, copolymers, terpolymers, interpolymers, and so on. “Polymer” also embraces all forms of copolymer, e.g., random, block, etc. An “interpolymer” is a polymer prepared by the polymerization of at least two types of monomers or comonomers. “Interpolymer” includes, but is not limited to, copolymers (which usually refers to polymers prepared from two different types of monomers or comonomers), terpolymers (which usually refers to polymers prepared from three different types of monomers or comonomers), tetrapolymers (which usually refers to polymers prepared from four different types of monomers or comonomers), and the like. The terms “ethylene/α-olefin polymer” and “propylene/α-olefin polymer” are indicative of copolymer as described above prepared from polymerizing ethylene or propylene respectively and one or more additional, polymerizable α-olefin monomer. It is noted that although a polymer is often referred to as being “made of” one or more specified monomers, “based on” a specified monomer or monomer type, “containing” a specified monomer content, or the like, in this context the term “monomer” is understood to be referring to the polymerized remnant of the specified monomer and not to the unpolymerized species. In general, polymers herein are referred to as being based on “units” that are the polymerized form of a corresponding monomer.

A “polypropylene polymer,” “propylene-based polymer,” or “propylene polymer,” is a polymer that contains equal to or greater than 50 wt %, or a majority amount of, polymerized propylene monomer (based on the total weight of the polymer) and, optionally, may contain at least one comonomer. The generic term “polypropylene” thus includes propylene homopolymer, propylene interpolymer, a blend of two or more propylene homopolymers, a blend of two or more propylene interpolymers, and a blend of one or more propylene homopolymers with one or more propylene interpolymers.

“Polystyrene” is an aromatic polymer prepared from styrene monomer as the only type of monomer. Thus, polystyrene is a styrene homopolymer. The generic term “polystyrene” includes impact modified polystyrene.

A “styrenic block copolymer” is an elastomer having at least one block segment of a styrenic monomer in combination with another block segment of another comonomer. The structure of the styrene block copolymers can be of the linear or radial type, and of the diblock or triblock type. Styrenic block copolymers are available from Dexco Polymers under the trademark VECTOR, from Kraton Corporation under the trademark KRATON, and from Dynasol under the trademark SOLPRENE.

A “thermoplastic” material is a linear or branched polymer which can be repeatedly softened and made flowable when heated and returned to a hard state when cooled to room temperature. In addition, thermoplastics can be molded or extruded into articles of any predetermined shape when heated to the softened state.

(A) Polypropylene Polymer

The present composition comprises a polypropylene polymer. In certain embodiments, the present composition comprises from 50 wt % to 99.99 wt % (e.g., from 50 wt % to 90 wt %, from 50 wt % to 85 wt %, from 50 wt % to 80 wt %, from 55 wt % to 75 wt %, from 60 wt % to 70 wt %, from 60 wt % to 65 wt %, from 61 wt % to 64 wt %, and/or from 62 wt % to 63 wt %) of a polypropylene polymer, based on the total weight of the composition. Said in another way, in certain embodiments, the composition includes from 50 wt %, or 55 wt %, or 60 wt %, or 61 wt %, or 62 wt % to 63 wt %, or 64 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt %, or 85 wt %, or 90 wt %, or 99.99 wt % of a polypropylene polymer, based on the total weight of the composition.

In certain embodiments, the polypropylene polymer contains from greater than 50 wt %, or 60 wt %, or 70 wt %, or 75 wt % to 80 wt %, or 90 wt %, or 95 wt %, or 98 wt %, or 99 wt %, or 100 wt % polymerized propylene monomer, based on the total weight of the polymer. The remainder of the polypropylene polymer is derived from units of ethylene and/or an α-olefin having from 4, or 6 to 8, or 12, or 16, or 20 carbon atoms. In an embodiment, the α-olefin is a C₄-C₂₀ linear, branched, or cyclic α-olefin.

Nonlimiting examples of suitable polypropylene polymers include polypropylene homopolymer (such as Braskem™ Polypropylene H502-25RZ); polypropylene random copolymer (such as Braskem™ Polypropylene R751-12N); polypropylene impact copolymer (such as YUPLENE™ BX3900 available from SK Global Chemical and Braskem™ Polypropylene T702-12N); graft polypropylene copolymers; and block propylene copolymers (such as polypropylene olefin block copolymers (PP-OBC) available from The Dow Chemical Company).

In various embodiments, the polypropylene polymer is a polypropylene impact copolymer.

In various embodiments, the polypropylene polymer has a density from 0.890 to 0.920 g/cm³ (e.g., from 0.890 to 0.915 g/cm³, from 0.890 to 0.910 g/cm³, from 0.895 to 0.905 g/cm³, etc.) in accordance with ASTM D792. Said in another way, in various embodiments, the polypropylene polymer has a density from 0.890 g/cm³, or 0.895 g/cm³, or 0.900 g/cm³ to 0.905 g/cm³, or 0.910 g/cm³, or 0.915 g/cm³, or 0.920 g/cm³ in accordance with ASTM D792.

In various embodiments, the polypropylene polymer has a melt flow rate from 1 g/10 min to 200 g/10 min (e.g., from 1 g/10 min to 150 g/10 min, from 15 g/10 min to 100 g/10 min, from 30 g/10 min to 100 g/10 min, from 40 to 90 g/10 min, from 45 to 80 g/10 min, from 50 to 70 g/10 min, from 55 to 65 g/10 min, etc.) in accordance with ASTM D1238 at 230° C./2.16 kg. Said in another way, in various embodiments, the polypropylene polymer has a melt flow rate from 1 g/10 min, or 15 g/10 min, or 30 g/10 min, or 40 g/l0 min, or 50 g/10 min, or 55 g/10 min, or 60 g/10 min to 65 g/10 min, or 70 g/10 min, or 80 g/10 min, or 90 g/10 min, or 100 g/10 min, or 150 g/10 min, or 200 g/10 min according to ASTM D1238 at 230° C./2.16 kg.

Polypropylene suitable for use herein can have one, some, or all of the following properties:

(a) a density from 0.890 g/cm³, or 0.895 g/cm³, or 0.900 g/cm³ to 0.905 g/cm³, or 0.910 g/cm³, or 0.915 g/cm³, or 0.920 g/cm³ in accordance with ASTM D792; and/or

(b) a melt flow rate from 50 g/10 min, or 55 g/10 min, or 60 g/10 min to 65 g/10 min, or 70 g/10 min, or 80 g/10 min, or 90 g/10 min, or 100 g/10 min in accordance with ASTM D1238 at 230° C./2.16 kg.

In one or more embodiments, the polypropylene polymer is a polypropylene impact copolymer with a density of 0.900 g/cm³ (ASTM D792) and a melt flow rate of 60 g/10 min (ASTM D1238, 230° C./2.16 kg).

The polypropylene polymer may comprise one or more embodiments disclosed herein.

(B) Elastomer Component

The present composition comprises an elastomer component. In certain embodiments, the present composition comprises from 0 wt % to 35 wt % (e.g., from 5 wt % to 35 wt %, from 10 wt % to 35 wt %, from 15 wt % to 30 wt %, from 15 wt % to 25 wt %, from 20 wt % to 25 wt %, from 20 wt % to 23 wt %, and/or from 20 wt % to 21 wt %) of an elastomer component, based on the total weight of the composition. Said in another way, in certain embodiments, the composition comprises from 0 wt %, or 5 wt %, or 10 wt %, or 15 wt %, or 20 wt % to 21 wt %, or 23 wt %, or 25 wt %, or 30 wt %, or 35 wt % of an elastomer component, based on the total weight of the composition.

The elastomer component of the present composition may be a polyolefin elastomer, a styrenic block copolymer, an elastomeric alloy, a thermoplastic polyurethane, a thermoplastic copolyester, a thermoplastic polyamide, or combinations thereof. In certain embodiments, the elastomer component of the present composition is a polyolefin elastomer.

In certain embodiments, the polyolefin elastomer of the present composition is a polyolefin elastomer or a mixture of polyolefin elastomers. A “polyolefin elastomer” is an elastomeric polymer containing at least 50 mole percent (mol %) of units derived from one or more α-olefins (based on the total amount of polymerizable monomers), or that contains equal to or greater than 50 wt %, or a majority amount of, polymerized α-olefin monomer (based on the total weight of the elastomer). In various embodiments, the polyolefin elastomers consist of only polymerized α-olefin monomer, including ethylene. Such polyolefin elastomers can be either homopolymers or interpolymers. Examples of polyolefin homopolymers are homopolymers of ethylene or propylene. Examples of polyolefin interpolymers are ethylene/α-olefin interpolymers and propylene/α-olefin interpolymers. In such embodiments, the α-olefin can be a C₃₋₂₀ linear, branched or cyclic α-olefin (for the propylene/α-olefin interpolymers, ethylene is considered an α-olefin). Examples of C₃₋₂₀ α-olefins include propene, 1-butene, 4-methyl-1-pentene, 1-hexene, 1-octene, 1-decene, 1-dodecene, 1-tetradecene, 1-hexadecene, and 1-octadecene. The α-olefins can also contain a cyclic structure such as cyclohexane or cyclopentane, resulting in an α-olefin such as 3-cyclohexyl-1-propene (allyl cyclohexane) and vinyl cyclohexane. Illustrative polyolefin copolymers include ethylene/propylene, ethylene/butene, ethylene/1-hexene, ethylene/1-octene, and the like. Illustrative terpolymers include ethylene/propylene/1-octene, ethylene/propylene/butene, and ethylene/butene/1-octene. In an embodiment, the polyolefin elastomer is an ethylene/octene copolymer. Additionally, the copolymers can be random or blocky.

Polyolefin elastomers can also comprise one or more functional groups such as an unsaturated ester or acid or silane, and these elastomers (polyolefins) are well known and can be prepared by conventional high-pressure techniques. The unsaturated esters can be alkyl acrylates, alkyl methacrylates, or vinyl carboxylates. The alkyl groups can have 1 to 8 carbon atoms and preferably have 1 to 4 carbon atoms. The carboxylate groups can have 2 to 8 carbon atoms and preferably have 2 to 5 carbon atoms. The portion of the copolymer attributed to the ester comonomer can be in the range of 1 up to 50 percent by weight based on the weight of the copolymer. Examples of the acrylates and methacrylates are ethyl acrylate, methyl acrylate, methyl methacrylate, t-butyl acrylate, n-butyl acrylate, n-butyl methacrylate, and 2-ethylhexyl acrylate. Examples of the vinyl carboxylates are vinyl acetate, vinyl propionate, and vinyl butanoate. Examples of the unsaturated acids include acrylic acids or maleic acids. One example of an unsaturated silane is vinyl trialkoxysilane.

Functional groups can also be included in the polyolefin elastomer through grafting which can be accomplished as is commonly known in the art. In one embodiment, grafting may occur by way of free radical functionalization which typically includes melt blending the polyolefin elastomer, a free radical initiator (such as a peroxide or the like), and a compound containing a functional group. During melt blending, the free radical initiator reacts (reactive melt blending) with the polyolefin elastomer to form polymer radicals. The compound containing a functional group bonds to the backbone of the polymer radicals to form a functionalized polymer. Exemplary compounds containing functional groups include but are not limited to alkoxysilanes (e.g., vinyl trimethoxysilane, vinyl triethoxysilane) and vinyl carboxylic acids and anhydrides (e.g., maleic anhydride).

Commercial examples of polyolefin elastomers useful herein include very-low-density polyethylene (VLDPE) (e.g., FLEXOMER™ ethylene/I-hexene polyethylene made by The Dow Chemical Company); homogeneously branched, linear ethylene/α-olefin copolymers (e.g. branded as TAFMER™ by Mitsui Petrochemicals Company Limited and EXACT™ by Exxon Chemical Company); homogeneously branched, substantially linear ethylene/α-olefin copolymers (e.g., branded as AFFINITY™ Polyolefin Plastomers and ENGAGE™ Polyolefin Elastomers available from The Dow Chemical Company); amorphous polyolefins (APOs) (e.g., EASTOFLEX™ amorphous propylene homopolymer available from Eastman Chemical Company); olefin block copolymers (e.g., INFUSE™ and INTUNE™ Olefin Block Copolymers available from The Dow Chemical Company); polybutene-1 copolymers (e.g., Koattro plastomers available from Lyondellbasell); and combinations thereof. In various embodiments, the polyolefin elastomers are the homogeneously branched linear and substantially linear ethylene/α-olefin copolymers. The substantially linear ethylene copolymers are more fully described in U.S. Pat. Nos. 5,272,236; 5,278,272 and 5,986,028. In another embodiment, the polyolefin elastomers are amorphous polyolefins, such as those more fully described in US Pub. No. 2004/0081795.

The polyolefin elastomers useful herein also include propylene-, butene-, and any other alkene-based copolymers. Such copolymers may comprise a majority (i.e., greater than 50 weight percent (wt %)) of units derived from the alkene (e.g., propylene) and a minority of units derived from another α-olefin (including ethylene). In an embodiment, the polyolefin elastomer includes a propylene-based copolymer. In further embodiments, the polyolefin elastomer comprises a propylene-ethylene copolymer. Exemplary propylene-based copolymers useful herein include VERSIFY™ Propylene Based Elastomer available from The Dow Chemical Company, and VISTAMAXX™ polymers available from ExxonMobil Chemical Company. When the component (B) polyolefin elastomer includes a polypropylene, it is different than the component (A) polypropylene.

Polyolefin elastomers can also include ethylene/propylene/diene monomer (EPDM) terpolymer elastomers and chlorinated polyethylenes (CPE). Commercial examples of suitable EPDMs include NORDEL™ EPDMs, available from The Dow Chemical Company. Commercial examples of suitable CPEs include TYRIN™ CPEs, available from The Dow Chemical Company.

In one or more embodiments, the polyolefin elastomer is selected from the group consisting of ethylene-based polyolefin elastomers, propylene-based polyolefin elastomers, and combinations thereof. In such embodiments, the ethylene-based polyolefin elastomer can have an ethylene content of greater than 50 wt %, or greater than 60 wt %, based on the entire weight of the ethylene-based polyolefin elastomer, with the balance consisting of one or more alpha-olefin monomers. Additionally, the ethylene-based polyolefin elastomer can have an ethylene content ranging from greater than 50 wt %, or 60 wt % to 75 wt %, or 90 wt %, based on the entire weight of the ethylene-based polyolefin elastomer, with the balance consisting of one or more alpha-olefin monomers. In various embodiments, the alpha-olefin monomer is octene.

Furthermore, when the polyolefin elastomer is propylene-based, it can have a propylene content of greater than 50 wt %, greater than 70 wt %, or greater than 90 wt %, based on the entire weight of the propylene-based polyolefin elastomer, with the balance consisting of one or more alpha-olefin monomers (including ethylene). Additionally, the propylene-based polyolefin elastomer can have a propylene content ranging from greater than 50 wt %, or 70 wt %, or 90 wt % to 97 wt %, or 98 wt %, or 99 wt %, based on the entire weight of the propylene-based polyolefin elastomer, with the balance consisting of one or more alpha-olefin monomers (including ethylene). In various embodiments, when the polyolefin elastomer is propylene-based, the alpha-olefin comonomer is ethylene. Nonlimiting examples of a suitable propylene-based polyolefin elastomer include propylene copolymer and propylene homopolymer. When the component (B) polyolefin elastomer includes a polypropylene, it is different than the component (A) polypropylene.

In one or more embodiments, the polyolefin elastomer is an ethylene/octene copolymer.

Polyolefin elastomers suitable for use herein can have a density, in accordance with ASTM D792, from 0.850 g/cm³ to 0.930 g/cm³ (e.g., from 0.850 g/cm³ to 0.920 g/cm³, from 0.850 g/cm³ to 0.910 g/cm³, from 0.850 g/cm³ to 0.900 g/cm³, from 0.850 g/cm³ to 0.890 g/cm³, from 0.860 g/cm³ to 0.880 g/cm³, from 0.865 g/cm³ to 0.875 g/cm³, etc.). Said in another way, in various embodiments, a polyolefin elastomer suitable for use herein has a density from 0.850 g/cm³, or 0.860 g/cm³, or 0.865 g/cm³ to 0.875 g/cm³, or 0.880 g/cm³, or 0.890 g/cm³, or 0.900 g/cm³, or 0.910 g/cm³, or 0.920 g/cm³, or 0.930 g/cm³ in accordance with ASTM D792.

Polyolefin elastomers suitable for use herein can have a melt index from 0.1 g/10 min to 100 g/10 min (e.g., from 0.1 g/10 min to 75 g/10 min, from 0.1 g/10 min to 50 g/10 min, from 0.1 g/10 min to 40 g/10 min, from 0.1 g/10 min to 30 g/10 min, from 0.1 g/10 min to 20 g/10 min, from 0.1 g/10 min to 15 g/10 min, from 0.5 g/10 min to 10 g/10 min, from 0.5 g/10 min to 8 g/10 min, from 1 g/10 min to 8 g/10 min, from 2 g/10 min to 8 g/10 min, from 3 g/10 min to 7 g/10 min, from 4 g/10 min to 6 g/10 min, etc.) in accordance with ASTM D1238 at 190° C./2.16 kg). Said in another way, in certain embodiments, polyolefin elastomers suitable for use herein can have a melt index from 0.1 g/10 min, or 0.5 g/10 min, or 1 g/10 min, or 2 g/10 min, or 3 g/10 min, or 4 g/10 min, or 5 g/10 min to 6 g/10 min, or 8 g/10 min, or 10 g/10 min, or 15 g/10 min, or 20 g/10 min, or 30 g/10 min, or 40 g/10 min, or 50 g/10 min, or 75 g/10 min, or 100 g/10 min in accordance with ASTM D1238 at 190° C./2.16 kg.

Polyolefin elastomers suitable for use herein can have one or both of the following properties:

(a) a density from 0.850 g/cm³, or 0.860 g/cm³, or 0.865 g/cm³, or 0.870 g/cm³ to 0.880 g/cm³, or 0.890 g/cm³, or 0.900 g/cm³, or 0.905 g/cm³, or 0.910 g/cm³, or 0.920 g/cm³, or less than 0.930 g/cm³ in accordance with ASTM D792; and/or

(b) a melt index from 0.1 g/10 min, or 0.5 g/10 min, or 1 g/10 min, or 2 g/10 min, or 3 g/10 min, or 4 g/10 min, or 5 g/10 min to 6 g/10 min, or 8 g/10 min, or 10 g/10 min, or 15 g/10 min, or 20 g/10 min, or 30 g/10 min, or 40 g/10 min, or 50 g/10 min in accordance with ASTM D1238 at 190° C./2.16 kg.

In one or more embodiments, the polyolefin elastomer includes an ethylene/octene copolymer with a density of 0.870 g/cm³ (ASTM D792) and a melt index of 5 g/10 min (ASTM D1238, 190° C./2.16 kg).

The polyolefin elastomer may comprise one or more embodiments disclosed herein.

(C) Compound Having the Formula (I)

The present composition comprises a compound having the formula (I):

wherein R1, R2, and R3 are each independently H, a linear or branched alkyl group having 1 to 10 carbon atoms, a hydroxyl group, a phenyl group, a halogen, —CO2CH3, or —CN.

In certain embodiments, the composition comprises from 0.01 wt % to 20 wt % (e.g., from 0.01 wt % to 10 wt %, from 0.01 wt % to 8 wt %, from 0.05 wt % to 6 wt %, from 0.1 wt % to 5 wt %, from 0.1 wt % to 3 wt %, from 0.1 wt % to 2 wt %, from 0.1 wt % to 1 wt %, from 0.1 wt % to 0.5 wt %, from 0.15 wt % to 0.45 wt %, etc.) of the compound having the formula (I), based on the total weight of the composition. Said in another way, in certain embodiments, the composition includes from 0.01 wt %, or 0.05 wt %, or 0.1 wt %, or 0.15 wt % to 0.45 wt %, or 0.5 wt %, or 1 wt %, or 2 wt %, or 3 wt %, or 5 wt %, or 6 wt %, or 8 wt %, or 10 wt %, or 20 wt % of the compound having the formula (I), based on the total weight of the composition.

In certain embodiments, the compound having the formula (I) includes barbituric acid (pyrimidine-2,4,6(1H,3H,5H)-trione) and its derivatives.

In certain embodiments, derivatives of barbituric acid include, but are not limited to, the following: 1,3-dimethylpyrimidine-2,4,6 (1H,3H,5H)-trione, 1-methyl-2,4,6-trioxo-hexahydro-pyrimidine, 1,5-dimethyl-2,4,6-trioxohexahydro-pyrimidine, 1,1,3-trimethyl-3-(1-(3-methyl-2,4,6-trioxotetrahydropyrimidin-1(2H)-yl)hexyl)urea, 1-ethyl-2,4,6-trioxo-hexahydro-pyrimidine, and 1-phenyl-2,4,6-trioxo-hexahydro-pyrimidine. Exemplary structures of these barbituric acid derivatives are shown below.

In certain embodiments, the compound having the formula (I) is a barbituric acid compound. Barbituric acid compounds suitable for the present disclosure include, but are not limited to, those that are commercially available from, e.g., SCR Co. Ltd., TCI Research Chemicals Co. Ltd., and Alfa Aesar Co. Ltd.

The compound having the formula (I) may comprise one or more embodiments disclosed herein.

(D) Additive Component

In certain embodiments, the present composition may comprise an additive component, which includes one or more optional additives. In certain embodiments, the present composition comprises from 0 wt % to 49.99 wt % (e.g., from 0 wt % to 45 wt %, from 0 wt % to 40 wt %, from 0 wt % to 30 wt %, from 5 wt % to 25 wt %, from 10 wt % to 20 wt %, from 12 wt % to 18 wt %, from 15 wt % to 18 wt %, and/or from 16 wt % to 17 wt %) of an additive component, based on the total weight of the composition. Said in another way, in certain embodiments, the present composition comprises from 0 wt %, or 5 wt %, or 10 wt %, or 12 wt %, or 15 wt %, or 16 wt % to 17 wt %, or 18 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 40 wt %, or 45 wt %, or 49.99 wt % of an additive component, based on the total weight of the composition.

Conventional additives, which can be introduced into the composition, are exemplified by talc, antioxidants, mineral oil, pigments, processing aids, flame retardants, ultraviolet (UV) stabilizers, reinforcing filler, calcium carbonate, mica, glass fibers, whisker, anti-scratch additives, and combinations thereof.

In certain embodiments, the composition includes talc, such as JetFi™ 700, available from IMERYS. Talc may be used in amounts of from 0 wt %, or 1 wt %, or 5 wt %, or 10 wt %, or 15 wt %, or 16 wt % to 17 wt %, 18 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 49.99 wt %, based on the total weight of the composition.

Nonlimiting examples of suitable antioxidant include tris(2,4-ditert-butylphenyl)phosphite, pentaerythritol tetrakis[3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionate], and combinations thereof. In an embodiment, the composition contains an antioxidant such as IRGANOX™ B 225, which contains a blend of 50 wt % tris(2,4-ditert-butylphenyl)phosphite and 50 wt % pentaerythritol tetrakis[3-[3,5-di-tert-butyl-4-hydroxyphenyl]propionate]. Antioxidant is may be used in amounts of from 0 wt %, or 0.05 wt %, or 0.1 wt %, or 0.2 wt % to 0.3 wt %, or 0.5 wt %, or 1 wt %, or 2 wt %, based on the total weight of the composition.

In an embodiment, the composition includes a processing aid. Nonlimiting examples of suitable processing aids include calcium stearate. Processing aids may be used in amounts of from 0 wt %, or 0.05 wt %, or 0.1 wt % to 0.5 wt %, or 1 wt %, or 2 wt %, based on the total weight of the composition.

In an embodiment, the composition includes an ultraviolet (UV) stabilizer. Nonlimiting examples of suitable ultraviolet (UV) stabilizer include hindered amine light stabilizer (HALS) such as bis(2,2,6,6,-tetramethyl-4-piperidyl)sebaceate (commercially available as Tinuvin™ 770 from BASF) and poly[[6-[(1,1,3,3-tetramethylbutyl)amino]-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidinyl)imino]-1,6-hexanediyl[(2,2,6,6-tetramethyl-4-piperidinyl)imino]] (commercially available as Chimassorb™ 944 from BASF). UV stabilizers may be used in amounts of from 0.05 wt %, or 0.1 wt %, or 0.5 wt % to 1 wt %, or 2 wt %, based on the total weight of the composition.

In an embodiment, the composition includes a reinforcing filler. Nonlimiting examples of reinforcing filler include glass fiber, mica, whisker, calcium carbonate (CaCO₃), and combinations thereof. Reinforcing filler may be used in amounts of from 2 wt %, or 5 wt % to 10 wt %, or 15 wt %, or 20 wt %, based on the total weight of the composition.

In an embodiment, the composition includes talc and an antioxidant.

In an embodiment, the composition includes from 0 wt %, or greater than 0 wt %, or 1 wt %, or 5 wt %, or 10 wt %, or 15 wt %, or 16 wt % to 17 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 35 wt %, or 40 wt %, or 45 wt %, or 49.99 wt % total additives, based on the total weight of the composition.

The additive may comprise one or more embodiments disclosed herein.

(E) Compatibilizer

In certain embodiments, the present composition may optionally include a compatibilizer. In certain embodiments, the present composition comprises from 0 wt % to 10 wt % of a compatibilizer, based on the total weight of the composition. In certain embodiments, the present composition comprises from 0 wt %, or 0.01 wt %, or 0.05 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, or 0.6 wt % to 0.8 wt %, or 1.0 wt %, or 1.5 wt %, or 2.0 wt %, or 3.0 wt %, or 4.0 wt %, or 5.0 wt %, or 8.0 wt %, or 10 wt % of the ompatibilizer, based on the total weight of the composition.

The compatibilizer may be a styrenic block copolymer, an ethylene acrylic acid (EAA) copolymer, an ethylene ethyl acrylate (EEA) copolymer, a block composite, a specified block composite, a crystalline block composite, an ethylene/vinyl acetate (EVA) copolymer, an ethylene-carboxylic acid copolymer, an ionomer, an ethylene methacrylic acid copolymer or an ethylene isobutyl acrylate copolymer, terpolymers of acrylates and acids, or an ethylene dipolymer E/A, wherein E is ethylene; A is acrylic or methacrylic acid, or an ethylene terpolymer E/A/B, wherein E is ethylene; A is acrylic or methacrylic acid; and B is n-butyl or isobutyl acrylate, or an ethylene terpolymer E/X/Y, wherein E is ethylene; X is vinyl acetate or a C1-C8 alkyl acrylate; and Y is CO or SO₂, or combinations thereof, or salts thereof, or neutralized versions thereof. In various embodiments, the compatibilizer could also be an ethylene dipolymer E/A or an ethylene terpolymer E/A/B, wherein E is ethylene; A is acrylic or methacrylic acid; and B is n-butyl or isobutyl acrylate; the weight proportion of monomer A in both the dipolymer and the terpolymer being about 2-20%, and the weight proportion of monomer B in the 20 terpolymer being at most about 23%; the carboxylic acid groups in either type of polymer being either unneutralized or neutralized to an extent of at most about 71% with metal ions having a valency of from 1 to 3. Both E/A dipolymers and E/A/B terpolymers are well known and commercially available; some, for example, from E. I. du Pont de Nemours and Company and ethylene/acrylic acid copolymer from Dow Chemical Co. Neutralized di- and terpolymers also are available, i.a., from E. I. du Pont de Nemours and Company. An exemplary amount of acrylic or methacrylic acid in a dipolymer or terpolymer is 8-15 weight percent. A further exemplary amount of a polymer of this group is about 75-90 parts. When the carboxylic acid groups are neutralized, the neutralizing metal ions are preferably sodium, zinc, magnesium, or aluminum, but may also be other metals from the first 25 three groups of the Periodic Chart of the Elements.

In various embodiments, the compatibilizer could also be a an ethylene terpolymer E/X/Y, where E is ethylene; X is vinyl acetate or a C1-C8 alkyl acrylate; and Y is CO or SO₂; the weight proportions of X and Y being as follows: Y about 1-15%; X, when it is vinyl acetate, about 15-30%, and when it is an alkyl acrylate, about 10-55%. The E/X/Y terpolymers are commercially available, while others can be made according to known processes. For example, E/VA/CO terpolymers, when VA is vinyl acetate, are available under the 30 name ElvaloyD from E. I. du Pont de Nemours and Company. The carbon monoxide content in those terpolymers in which X is vinyl acetate should preferably be no higher than about 7% by weight; otherwise, polymer compatibility may be adversely 35 affected. Terpolymers in which Y is SO2 are described in U.S. Pat. No. 3,684,778 to Hammer, and terpolymers in which X is an alkyl acrylate are described in U.S. Pat. No. 2,495,286 to Brubaker. The preferred terpolymer in which X is an alkyl acrylate 5 is an ethylene/n-butyl acrylate/CO terpolymer, which can be made according to the general method taught by Brubaker. The weight proportion of n-butyl acrylate in the terpolymer is about 15-35%. Other typical alkyl acrylates and their weight proportions in the 10 terpolymer include the following: methyl acrylate (15-55%), ethyl acrylate (15-40%), and t-butyl acrylate (10-25%). The preferred amount of E/X/Y terpolymer in the composition is 10-30 parts. Other alkyl acrylates include, among others, propyl, isopropyl, pentyl, hexyl, heptyl, octyl, and isooctyl acrylates.

Suitable compatibilizers may include, but are not limited to those disclosed in EP134501A1, which is incorporated herein by reference.

In various embodiments, the compatibilizer is a styrenic block copolymer. The styrenic block copolymer may be any styrenic block copolymer disclosed herein. In an embodiment, the styrenic block copolymer is SEBS.

Styrenic block copolymer suitable for use herein can have, in accordance with D792, a density from 0.850 g/cm³, or 0.860 g/cm³, or 0.870 g/cm³, or 0.880 g/cm³ to 0.885 g/cm³, or 0.890 g/cm³, or 0.900 g/cm³.

Styrenic block copolymer suitable for use herein can have, in accordance with D1238 (230° C./5.00 kg), a melt flow rate from 5 g/10 min, or 10 g/10 min, or 15 g/10 min, or 20 g/10 min to 25 g/10 min, or 30 g/10 min, or 40 g/10 min, or 50 g/10 min.

Styrenic block copolymer suitable for use herein can have one or both of the following properties:

(a) a density from 0.850 g/cm³, or 0.860 g/cm³, or 0.870 g/cm³, or 0.880 g/cm³ to 0.885 g/cm³, or 0.890 g/cm³, or 0.900 g/cm³; and/or

(b) a melt flow rate from 5 g/10 min, or 10 g/10 min, or 15 g/10 min, or 20 g/10 min to 25 g/10 min, or 30 g/10 min, or 40 g/10 min, or 50 g/10 min (230° C./5.00 kg).

In one or more embodiments, the compatibilizer is a styrenic block copolymer that is SEBS having a density of 0.880 g/cm³ and a melt flow rate of 22 g/10 min (230° C./5.00 kg).

In various embodiments, the compatibilizer is an ethylene acrylic acid (EAA) copolymer. The EEA copolymer may contain from 1 wt %, or 5 wt %, or 10 wt %, or 12 wt %, or 15 wt %, or 18 wt % to 19 wt %, or 20 wt %, or 25 wt %, or 30 wt %, or 40 wt %, or less than 50 wt % polymerized ethyl acrylate, based on the total weight of the EEA copolymer. EEA copolymer suitable for use herein can have, in accordance with ASTM D792, a density from 0.920 g/cm³, or 0.925 g/cm³, or 0.930 g/cm³ to 0.935 g/cm³, or 0.940 g/cm³, or 0.945 g/cm³. EEA copolymer suitable for use herein can have, in accordance with ASTM D1238 (190° C./2.16 kg), a melt index from 0.5 g/10 min, or 1 g/10 min, or 2 g/10 min, or 5 g/10 min to 6 g/10 min, or 8 g/10 min, or 10 g/10 min, or 15 g/10 min, or 20 g/10 min.

In one or more embodiments, the compatibilizer is an EEA copolymer containing 18.5 wt % polymerized ethyl acrylate, based on the total weight of the EEA copolymer, that has a density of 0.931 g/cm³ (ASTM D792) and a melt index of 6.0 g/10 min (ASTM D1238, 190° C./2.16 kg).

In an embodiment, the compatibilizer is a block composite. “Block composite” refers to polymers comprising an ethylene based polymer (EP) (soft copolymer) having an ethylene content of from 10 mol % to 90 mol %, an alpha-olefin based polymer (AOP) (hard copolymer) having an alpha-olefin content of greater than 90 mol %, and a block copolymer (diblock) having an ethylene block/segment (EB) and an alpha-olefin block/segment (AOB), wherein the ethylene block of the block copolymer is the same composition as the ethylene based polymer of the block composite and the alpha-olefin block of the block copolymer is the same composition as the alpha-olefin based polymer of the block composite. The compositional split between the amount of ethylene based polymer and alpha-olefin based polymer will be essentially the same as that between the corresponding blocks in the block copolymer. The block composite of the present disclosure is similar to those disclosed in U.S. Pat. Nos. 8,053,529; 8,686,087; and 8,716,400, which are incorporated herein by reference.

In an embodiment, the compatibilizer is a specified block composite. “Specified block composite” refers to polymers comprising an ethylene based polymer (EP) (soft copolymer) having an ethylene content of from 78 mol % to 90 mol %, an alpha-olefin based polymer (AOP) (hard copolymer) having an alpha-olefin content of from 61 mol % to 90 mol %, and a block copolymer (diblock) having an ethylene block/segment (EB) and an alpha-olefin block/segment (AOB), wherein the ethylene block of the block copolymer is the same composition as the ethylene based polymer of the specified block composite and the alpha-olefin block of the block copolymer is the same composition as the alpha-olefin based polymer of the specified block composite. The compositional split between the amount of ethylene based polymer and alpha-olefin based polymer will be essentially the same as that between the corresponding blocks in the block copolymer. The specified block composite of the present disclosure is similar to those disclosed in WO 2017/044547, which is incorporated herein by reference.

In an embodiment, the compatibilizer is a crystalline block composite. “Crystalline block composite” refers to polymers comprising a crystalline ethylene based polymer (CEP) having an ethylene content of greater than 90 mol %, a crystalline alpha-olefin based polymer (CAOP) having an alpha-olefin content of greater than 90 mol %, and a block copolymer (diblock) having a crystalline ethylene block (CEB) and a crystalline alpha-olefin block (CAOB), wherein the CEB of the block copolymer is the same composition as the CEP of the crystalline block composite and the CAOB of the block copolymer is the same composition as the CAOP of the crystalline block composite. The compositional split between the amount of CEP and CAOP will be essentially the same as that between the corresponding blocks in the block copolymer. The crystalline block composite of the present disclosure is similar to those disclosed in WO 2016/0028961 A1, which is incorporated herein by reference.

The compatibilizer may comprise one or more embodiments disclosed herein.

Composition

The present disclosure provides a composition, and further a thermoplastic polyolefin composition comprising:

(A) a polypropylene polymer;

(B) an elastomer component;

(C) a compound having the formula (I):

-   -   wherein R1, R2, and R3 are each independently H, a linear or         branched alkyl group having 1 to 10 carbon atoms, a hydroxyl         group, a phenyl group, a halogen, —CO2CH3, or —CN;

(D) an optional additive component; and

(E) an optional compatibilizer.

In certain embodiments, the present disclosure provides a thermoplastic polyolefin composition comprising:

(A) from 50 wt % to 99.99 wt % of a polypropylene polymer;

(B) from 0 wt % to 35 wt % of an elastomer component;

(C) from 0.01 wt % to 20 wt % of a compound having the formula (I):

-   -   wherein R1, R2, and R3 are each independently H, a linear or         branched alkyl group having 1 to 10 carbon atoms, a hydroxyl         group, a phenyl group, a halogen, —CO2CH3, or —CN;

(D) optionally, from 0 wt % to 49.99 wt % of an additive component; and

(E) optionally, from 0 wt % to 10 wt % of a compatibilizer.

In certain embodiments, the composition comprises a polypropylene polymer and the compound having the formula (I).

In certain embodiments, the composition includes:

(A) from 50 wt %, or 55 wt %, or 60 wt %, or 61 wt %, or 62 wt % to 63 wt %, or 64 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt %, or 85 wt % of a polypropylene impact copolymer;

(B) from 5 wt %, or 10 wt %, or 15 wt %, or 20 wt % to 21 wt %, or 23 wt %, or 25 wt %, or 30 wt %, or 35 wt % of an ethylene/octene copolymer;

(C) from 0.01 wt %, or 0.05 wt %, or 0.1 wt %, or 0.15 wt % to 0.45 wt %, or 0.5 wt %, or 1 wt %, or 2 wt %, or 3 wt %, or 5 wt %, or 6 wt %, or 8 wt %, or 10 wt %, 15 wt %, or 20 wt % of a barbituric acid compound;

(D) from 0 wt %, or 5 wt %, or 10 wt %, or 12 wt %, or 15 wt %, or 16 wt % to 17 wt %, or 18 wt %, or 20 wt %, or 25 wt %, or 30 wt % of an additive component selected from talc, antioxidant, processing aid, reinforcing filler, and combinations thereof; and

(E) from 0 wt %, or 0.01 wt %, or 0.05 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, or 0.6 wt % to 0.8 wt %, or 1.0 wt %, or 1.5 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 3.5 wt %, or 4.0 wt %, or 5.0 wt %, or 8.0 wt %, or 10 wt % of a compatibilizer selected from SEBS, EEA copolymer, EAA copolymer, or combinations thereof.

It is understood that the sum of the components in each of the foregoing compositions yields 100 weight percent.

In certain embodiments, the present composition includes at least four different components: (A) a polypropylene polymer, (B) an elastomer component, (C) a compound having the formula (I), and (D) an additive component. Thus, one component cannot serve as two components. For example, when each of the (A) polypropylene and (B) polyolefin elastomer are polypropylene, they are different polypropylenes.

The present composition advantageously causes aldehyde abatement (i.e., reduction) or scavenges aldehydes. Aldehydes can be dangerous to the health of humans and/or animals. Aldehydes can also be harmful to the environment. In addition, it is well known that aldehydes and ketones can contribute significantly to the generation of odor. Nonlimiting examples of aldehydes include formaldehyde, acetaldehyde, acrolein, propionaldehyde, and crotonaldehyde. Accordingly, the present composition reduces aldehydes and odor while surprisingly maintaining good mechanical properties.

In various embodiments, the present composition contains less than 0.01 mg/m³ formaldehyde, as measured in accordance with the VOC Test Method described below in the Test Methods section. In certain embodiments, the present composition contains from 0 mg/m³ to less than 0.01 mg/m³, or less than 0.02 mg/m³, or less than 0.03 mg/m³, or less than 0.05 mg/m³, or less than 0.10 mg/m³, or less than 0.18 mg/m³, or less than 0.20 mg/m³ formaldehyde, as measured in accordance with the VOC Test Method.

In various embodiments, the present composition contains less than 0.01 mg/m³ acetaldehyde, as measured in accordance with the VOC Test Method. In certain embodiments, the present composition contains from 0 mg/m³ to less than 0.01 mg/m³, or less than 0.05 mg/m³, or less than 0.10 mg/m³, or less than 0.30 mg/m³, or less than 0.50 mg/m³, or less than 0.90 mg/m³, or less than 1.00 mg/m³, or less than 1.30 mg/m³, or less than 1.50 mg/m³, or less than 1.55 mg/m³ acetaldehyde, as measured in accordance with the VOC Test Method.

In various embodiments, the present composition contains less than 0.01 mg/m³ acrolein, as measured in accordance with the VOC Test Method. In certain embodiments, the present composition contains from 0 mg/m³ to less than 0.01 mg/m³, or less than 0.02 mg/m³, or less than 0.03 mg/m³, or less than 0.05 mg/m³ acrolein, as measured in accordance with the VOC Test Method.

In certain embodiments, the present composition has a flexural modulus (Young's modulus) from 1200 MPa, or 1400 MPa, or 1500 MPa, or 1600 MPa, or 1700 MPa to 1800 MPa, or 1900 MPa, or 2000 MPa, as measured in accordance with ISO 178. In various embodiments, the present composition has a flexural modulus (Young's modulus) of greater than 1700 MPa, as measured in accordance with ISO 178.

In various embodiments, the present composition has a flexural yield strength from 20 MPa, or 25 MPa, or 30 MPa, or 31 MPa to 35 MPa, or 40 MPa, or 50 MPa, as measured in accordance with ISO 178. In various embodiments, the present composition has a flexural yield strength of greater than 30 MPa, as measured in accordance with ISO 178.

In various embodiments, the present composition has a tensile modulus from 1000 MPa, or 1200 MPa, or 1300 MPa, or 1400 Mpa, or 1500 MPa, or 1600 MPa, or 1700 MPa to 1800 MPa, or 1900 MPa, or 2000 MPa, as measured in accordance with ISO 527. In various embodiments, the present composition has a tensile modulus of greater than 1700 MPa, as measured in accordance with ISO 527.

In various embodiments, the present composition has a tensile yield strength from 10 MPa, or 15 MPa, or 18 MPa, or 20 MPa to 21 MPa, or 25 MPa, or 30 MPa, or 35 MPa, as measured in accordance with ISO 527. In various embodiments, the present composition has a tensile yield strength of greater than 20 MPa, as measured in accordance with ISO 527.

In various embodiments, the present composition has an impact strength (Notched IZOD) at 23° C. from 15 kJ/m², or 20 kJ/m², or 23 kJ/m², or 25 kJ/m² to 26 kJ/m², or 30 kJ/m², or 35 kJ/m², or 40 kJ/m², or 45 kJ/m², or 50 kJ/m², as measured in accordance with ISO 180. In various embodiments, the present composition has an impact strength (Notched IZOD) at 23° C. of greater than 23 kJ/m², as measured in accordance with ISO 180.

In various embodiments, the present composition has an impact strength (Notched IZOD) at −30° C. from 2 kJ/m², or 3.5 kJ/m², or 4.0 kJ/m², or 4.5 kJ/m² to 5.0 kJ/m², or 6.0 kJ/m², or 8.0 kJ/m², as measured in accordance with ISO 180. In various embodiments, the present composition has an impact strength (Notched IZOD) at −30° C. of greater than 4.20 kJ/m², as measured in accordance with ISO 180.

In various embodiments, the composition contains less than 0.01 mg/m³ formaldehyde, less than 0.01 mg/m³ acetaldehyde, and/or less than 0.01 mg/m³ acrolein, as measured in accordance with the VOC Test Method, and can have one, some, or all of the following properties:

(i) a flexural modulus from 1200 MPa, or 1400 MPa, or 1500 MPa, or 1600 MPa, or 1700 MPa to 1800 MPa, or 1900 MPa, or 2000 MPa, as measured in accordance with ISO 178;

(ii) a flexural yield strength from 20 MPa, or 25 MPa, or 30 MPa, or 31 MPa to 35 MPa, or 40 MPa, or 50 MPa, as measured in accordance with ISO 178;

(iii) a tensile modulus from 1000 MPa, or 1200 MPa, or 1300 MPa, or 1400 Mpa, or 1500 MPa, or 1600 MPa, or 1700 MPa to 1800 MPa, or 1900 MPa, or 2000 MPa, as measured in accordance with ISO 527;

(iv) a tensile yield strength from 10 MPa, or 15 MPa, or 18 MPa, or 20 MPa to 21 MPa, or 25 MPa, or 30 MPa, or 35 MPa, as measured in accordance with ISO 527;

(v) an impact strength (Notched IZOD) at 23° C. from 15 kJ/m², or 20 kJ/m², or 25 kJ/m² to 26 kJ/m², or 30 kJ/m², or 35 kJ/m², or 40 kJ/m², or 45 kJ/m², or 50 kJ/m², as measured in accordance with ISO 180; and/or

(vi) an impact strength (Notched IZOD) at −30° C. from 2 kJ/m², or 3.5 kJ/m², or 4.0 kJ/m², or 4.5 kJ/m² to 5.0 kJ/m², or 6.0 kJ/m², or 8.0 kJ/m², as measured in accordance with ISO 180.

In certain embodiments, the composition is non-aqueous. A “non-aqueous” composition excludes a solvent, such as water.

In certain embodiments, the composition excludes divalent metal ions such as zinc, calcium, magnesium, and zirconium.

In various embodiments, the composition is in the form of a pellet. The pellet may have a diameter from 2.0 mm, or 2.3 mm to 3.0 mm, or 3.5 mm and a length from 2.0 mm, or 2.3 mm to 3.0 mm, or 3.5 mm. In an embodiment, the composition is in the form of a pellet with a diameter from 2.3 mm to 3.0 mm and a length from 2.3 mm to 3.0 mm.

The present composition may comprise one or more embodiments disclosed herein.

Article

The present disclosure provides an article made from a thermoplastic polyolefin composition comprising:

(A) a polypropylene polymer;

(B) an elastomer component;

(C) a compound having the formula (I):

-   -   wherein R1, R2, and R3 are each independently H, a linear or         branched alkyl group having 1 to 10 carbon atoms, a hydroxyl         group, a phenyl group, a halogen, —CO2CH3, or CN;

(D) an optional additive component; and

(E) an optional compatibilizer.

In certain embodiments, an article of the present disclosure may be made from a thermoplastic polyolefin composition comprising a polypropylene polymer and the compound having the formula (I).

In various embodiments, an article of the present disclosure may be made from a thermoplastic polyolefin composition comprising:

(A) from 50 wt % to 99.99 wt % of a polypropylene polymer;

(B) from 0 wt % to 35 wt % an elastomer component;

(C) from 0.01 wt % to 20 wt % of a compound having the formula (I):

-   -   wherein R1, R2, and R3 are each independently H, a linear or         branched alkyl group having 1 to 10 carbon atoms, a hydroxyl         group, a phenyl group, a halogen, —CO2CH3, or CN;

(D) optionally, from 0 wt % to 49.99 wt % of an additive component; and

(E) optionally, from 0 wt % to 10 wt % of a compatibilizer.

In certain embodiments, an article of the present disclosure may be made from a composition comprising:

(A) from 50 wt %, or 55 wt %, or 60 wt %, or 61 wt %, or 62 wt % to 63 wt %, or 64 wt %, or 65 wt %, or 70 wt %, or 75 wt %, or 80 wt %, or 85 wt % of a polypropylene impact copolymer;

(B) from 5 wt %, or 10 wt %, or 15 wt %, or 20 wt % to 21 wt %, or 23 wt %, or 25 wt %, or 30 wt %, or 35 wt % of an ethylene/octene copolymer;

(C) from 0.01 wt %, or 0.05 wt %, or 0.1 wt %, or 0.15 wt % to 0.45 wt %, or 0.5 wt %, or 1 wt %, or 2 wt %, or 3 wt %, or 5 wt %, or 6 wt %, or 8 wt %, or 10 wt %, or 15 wt %, or 20 wt % of a barbituric acid compound;

(D) from 0 wt %, or 5 wt %, or 10 wt %, or 12 wt %, or 15 wt %, or 16 wt % to 17 wt %, or 18 wt %, or 20 wt %, or 25 wt %, or 30 wt % of an additive component selected from talc, antioxidant, processing aid, reinforcing filler, and combinations thereof; and

(E) from 0 wt %, or 0.01 wt %, or 0.05 wt %, or 0.1 wt %, or 0.2 wt %, or 0.3 wt %, or 0.4 wt %, or 0.5 wt %, or 0.6 wt % to 0.8 wt %, or 1.0 wt %, or 1.5 wt %, or 2.0 wt %, or 2.5 wt %, or 3.0 wt %, or 3.5 wt %, or 4.0 wt %, or 5.0 wt %, or 8.0 wt %, or 10 wt % of a compatibilizer selected from SEBS, EEA copolymer, EAA copolymer, or combinations thereof.

The composition may be any composition previously disclosed herein.

In various embodiments, the article is a molded article. The article may be formed by injection molding or compression molding.

The article may be in, but is not limited to, the form of an automobile interior part, such as an instrument panel, a door panel, or a seat.

In various embodiments, the article made from the present composition contains less than 0.01 mg/m³ formaldehyde, as measured in accordance with the VOC Test Method described below in the Test Methods section. In certain embodiments, the article made from the present composition contains from 0 mg/m³ to less than 0.01 mg/m³, or less than 0.02 mg/m³, or less than 0.03 mg/m³, or less than 0.05 mg/m³, or less than 0.10 mg/m³, or less than 0.18 mg/m³, or less than 0.20 mg/m³ formaldehyde, as measured in accordance with the VOC Test Method.

In various embodiments, the article made from the present composition contains less than 0.01 mg/m³ acetaldehyde, as measured in accordance with the VOC Test Method. In certain embodiments, the article made from the present composition contains from 0 mg/m³ to less than 0.01 mg/m³, or less than 0.05 mg/m³, or less than 0.10 mg/m³, or less than 0.30 mg/m³, or less than 0.50 mg/m³, or less than 0.90 mg/m³, or less than 1.00 mg/m³, or less than 1.30 mg/m³, or less than 1.50 mg/m³, or less than 1.55 mg/m³ acetaldehyde, as measured in accordance with the VOC Test Method.

In various embodiments, the article made from the present composition contains less than 0.01 mg/m³ acrolein, as measured in accordance with the VOC Test Method. In certain embodiments, the article made from the present composition contains from 0 mg/m³ to less than 0.01 mg/m³, or less than 0.02 mg/m³, or less than 0.03 mg/m³, or less than 0.05 mg/m³ acrolein, as measured in accordance with the VOC Test Method.

In various embodiments, the article made from the present composition contains less than 0.01 mg/m³ formaldehyde, less than 0.01 mg/m³ acetaldehyde, and/or less than 0.01 mg/m³ acrolein, as measured in accordance with the VOC Test Method, and can have one, some, or all of the following properties:

(i) a flexural modulus from 1200 MPa, or 1400 MPa, or 1500 MPa, or 1600 MPa, or 1700 MPa to 1800 MPa, or 1900 MPa, or 2000 MPa, as measured in accordance with ISO 178;

(ii) a flexural yield strength from 20 MPa, or 25 MPa, or 30 MPa, or 31 MPa to 35 MPa, or 40 MPa, or 50 MPa, as measured in accordance with ISO 178;

(iii) a tensile modulus from 1000 MPa, or 1200 MPa, or 1300 MPa, or 1400 Mpa, or 1500 MPa, or 1600 MPa, or 1700 MPa to 1800 MPa, or 1900 MPa, or 2000 MPa, as measured in accordance with ISO 527;

(iv) a tensile yield strength from 10 MPa, or 15 MPa, or 18 MPa, or 20 MPa to 21 MPa, or 25 MPa, or 30 MPa, or 35 MPa, as measured in accordance with ISO 527;

(v) an impact strength (Notched IZOD) at 23° C. from 15 kJ/m², or 20 kJ/m², or 23 kJ/m², or 25 kJ/m² to 26 kJ/m², or 30 kJ/m², or 35 kJ/m², or 40 kJ/m², or 45 kJ/m², or 50 kJ/m², as measured in accordance with ISO 180; and/or

(vi) an impact strength (Notched IZOD) at −30° C. from 2 kJ/m², or 3.5 kJ/m², or 4.0 kJ/m², or 4.5 kJ/m² to 5.0 kJ/m², or 6.0 kJ/m², or 8.0 kJ/m², as measured in accordance with ISO 180.

The present article may comprise one or more embodiments disclosed herein.

The present compositions and articles advantageously contain a low concentration of aldehydes, such as formaldehyde, acetaldehyde, and acrolein, while surprisingly maintaining or improving upon the mechanical properties necessary for automobile interior parts. Not wishing to be bound by any particular theory, Applicants believe the compound having the formula (I) (e.g., a barbituric acid compound or its derivatives) reacts with aldehydes present in the composition, such as by a nucleophilic addition reaction, which reduces the aldehyde concentration. A non-limiting example of the nucleophilic addition reaction is depicted in Equation (1) below, which depicts the abatement of aldehyde by an exemplary compound having the formula (I).

The exemplary compound having the formula (I) reduces the aldehyde concentration of the composition and/or the article and may reduce the aldehyde concentration of other automobile interior parts (such as when the compound reacts with aldehydes present in the interior air of an automobile). Further, the present compositions and articles exhibit a balance between toughness (demonstrated by the tensile impact properties such as IZOD testing) and stiffness (demonstrated by the tensile and flexural properties) that is advantageous for automobile interior parts.

By way of example, and not limitation, examples of the present disclosure are provided.

EXAMPLES

1. Test Methods

Density is measured in accordance with ASTM D792, Method B. The result is recorded in grams (g) per cubic centimeter (g/cc or g/cm³).

Melt flow rate (MFR) for polypropylene is measured in accordance with ASTM D1238, Condition 230° C./2.16 kilogram (kg) weight. The result is recorded in grams (g) eluted per 10 minutes (g/10 min).

Melt flow rate (MFR) for styrenic polymer, including polystyrene and styrenic block copolymer, is measured in accordance with ASTM D1238, Condition 230° C./5.00 kilogram (kg) weight. The result is recorded in g/10 min.

Melt index (MI) is measured in accordance with ASTM D1238, Condition 190° C./2.16 kilogram (kg) weight, also known as I₂. The result is reported g/10 min.

Notched IZOD Impact Strength is measured in accordance with ISO 180 at room temperature (23° C.) and at −30° C. The result is recorded in kilojoules (kJ) per square meter (kJ/m²).

Flexural modulus (Young's Modulus) is measured in accordance with ISO 178. The result is recorded in megaPascal, or MPa.

Flexural yield strength is measured in accordance with ISO 178. The result is recorded in megaPascal, or MPa.

Tensile modulus is measured in accordance with ISO 527. The result is recorded in megaPascal, or MPa.

Tensile yield strength is measured in accordance with ISO 527. The result is recorded in megaPascal, or MPa.

VOC Test Method: Volatile Organic Chemical (VOC) testing is performed in accordance with the “VOC Test Method” described below, which is revised from the Toyota™ gas bag method TSM 0508G. In the following working examples, samples are prepared by weighing each component and extruding using a Coperon 18 mm extruder. The compounds are granulated into small pellets by a side cutter granulator. The granulated compounds are used for testing using the VOC Test Method described below.

The VOC Test Method is performed by weighing 200 g of a sample into a 10 liter (L) gas volume Tedlar™ PVF (polyvinyl fluoride) bag (from Delin Co. ltd, China), and then feeding 5 L of nitrogen into the bag. The bag is then stored at 65° C. for two hours before analysis. The nitrogen gas in the gas bag is then pumped out by an air pump for carbonyls analysis. Further details of the carbonyls analysis.

Carbonyl analysis is performed with a 4 liter sample from the bag. The sample is derivatized with dinitrophenylhydrazine (DNPH). Then, the carbonyl compounds are extracted and injected into a high-performance liquid chromatography (HPLC) column and separated using gradient elution. The separated compounds are then quantified by UV detection at 360 nm, with a detection limit of 0.01 mg/m³. Carbonyl analysis provides the concentration of aldehydes, such as formaldehyde, acetaldehyde, acrolein, propionaldehyde, and crotonaldehyde present in the sample. Further details of the carbonyl analysis is provided in the paragraph below, as well as the HPLC conditions of Table 1.

DNPH cartridges (CNWBOND DNPH-Silica cartridge, 350 mg, Cat. No. SEEQ-144102, Anple Co. Ltd.) are employed to absorb the carbonyls emitted from the gas bag. The sampling speed is 330 mL/min and the sampling time is 13 min. After absorption, the DNPH cartridges are eluted with 1 gram (precisely weighed) of ACN, and the ACN solution is analyzed by HPLC to quantify the carbonyls in the sample. The standard solution with six DNPH derivatives (TOllA carbonyl-DNPH mix, Cat. No. 48149-U, 15 ppm for each individual compound, Supelco Co. Ltd.) is diluted by acetonitrile, and the final solution (0.794 ppm wt/wt) is restored in a 2 mL vial for instrument calibration at −4° C. (refrigerator). The 0.794 ppm (wt/wt) standard solution is injected into the HPLC system as a one point external standard for quantification of carbonyls in the sample. The first two peaks are identified as formaldehyde and acetaldehyde according to the standard specification. The response factor is calculated for each derivative according to the formula below:

${Response}\mspace{14mu} {factor}\mspace{14mu} {i = \frac{{Peak}\mspace{14mu} {Area}\mspace{14mu} i}{{0.7}94}}$

Where:

-   -   Response factor i=Response factor of derivative i     -   Peak Area i=Peak Area of derivative i in standard solution     -   0.794=standard concentration of 0.794 ppm

The concentration of the aldehyde-DNPH derivative in the sample solution is calculated based on the formula below:

${Concentration}\mspace{14mu} {of}\mspace{14mu} {i = \frac{{Peak}\mspace{14mu} {Area}\mspace{14mu} i}{{Response}\mspace{14mu} {factor}\mspace{14mu} i}}$

Where:

-   -   Concentration of i=Conc. of aldehyde-DNPH derivative in sample         solution     -   Peak Area i=Peak Area of Derivative i in sample solution     -   Response factor i=Response factor of derivative i

The HPLC conditions are shown below in Table 1.

TABLE 1 Instrument: Agilent 1200 HPLC Column: Supelco Ascentis Express C18, 15 cm*4.6 mm, 2.7 um Mobile Phase: Solvent A: 0.1% H₃PO₄ in Acetonitrile (ACN) Solvent B: 0.1% H₃PO₄ in DI water Column Oven: 15° C. Detection: DAD detector at 360 nm Gradient: Time (min) % A % B Flow(mVmin) 0 45 55 1 7 45 55 1 14 50 50 1 20 85 15 1 25 100 0 1 Equilibration 5 min Time: Injection: 10 uL

Differential Scanning Calorimetry (DSC): Glass transition temperature (Tg) of a polymer is measured by DSC. 5-10 milligram (mg) of a sample is analyzed in a crimped aluminum pan on a TA Instrument DSC Q2000 fitted with an auto-sampler under nitrogen. Tg measurement by DSC is conducted for 3 cycles: 1st cycle: from −60° C. to 160° C., 10 degree Celsius per minute (° C./min), and hold for 3 minutes (min); 2nd cycle: from 160° C. to −60° C., 10° C./min, hold for 3 min; and 3^(rd) cycle: from −60° C. to 160° C., 10° C./min, and hold for 3 min. Tg is obtained from the 3^(rd) cycle by the half height method.

Gel Permeation Chromatography (GPC): Molecular weight of a polymer is measured by GPC analysis using Agilent 1200. The sample is dissolved in tetrahydrofuran (THF)/formic acid (FA) (5%) with a concentration of 2 mg/mL and then filtered through 0.45 μm polytetrafluoroethylene (PTFE) filter prior to the GPC analysis. The GPC analysis is conducted using the following conditions:

Column: One PLgel GUARD columns (10 μm, 50×7.5 mm), One Mixed B columns (7.8×300 mm) in tandem; column temperature: 40° C.; mobile phase: THF/FA (5%); flow rate: 1.0 mL/minute; injection volume: 100 μL; detector: Agilent Refractive Index detector, 40° C.; and calibration curve: PL Polystyrene Narrow standards with molecular weights ranging from 2329000 to 580 g/mol, using polynom 3 fitness.

2. Materials

The materials used in the examples are provided in Table 2 below.

TABLE 2 Material Description/Properties Source YUPLENE ™ propylene impact copolymer SK Global BX3900 density = 0.90 g/cc (ASTM D792) Chemical MFR = 60 g/10 min (ASTM D1238, 230° C./2.16 kg) ENGAGE ™ polyolefin elastomer The Dow 8200 ethylene/octene copolymer Chemical density = 0.870 g/cc (ASTM D792) Company MI = 5 g/10 min (ASTM D792, 190° C./2.16 kg) Barbituric acid Barbituric acid (pyrimidine- SCR Co. Ltd. 2,4,6(1H,3H,5H)-trione) JetFil ™ 700 Talc IMERYS IRGANOX ™ Antioxidant containing a blend of BASF B 225 50 wt % tris(2,4-ditert- butylphenyl)phosphite and 50 wt % pentaerythritol tetrakis[3-[3,5- di-tert-butyl-4- hydroxyphenyl]propionate]

3. Protocols

a. Preparation of Inventive Examples 1-2 and Comparative Sample 1

The comparative sample and inventive examples are each prepared by weighing each component into a Coperon™ 18 mm extruder and extruding the composition. After extrusion, the composition is granulated into small pellets using a side cutter granulator manufactured by LABTECH Engineering company, Model: LSC-108. Pellets have a diameter of 2.3˜3.0 mm and a length of 2.3˜3.0 mm. The pellets are then molded into samples for testing. Table 3 shows the amount, in phr and approximate weight percent, of each component included in the example and comparative sample compositions.

The pellets are tested for Volatile Organic Chemicals (VOC) via the VOC Method described above. The results are shown in Table 3.

The pellets are also tested for mechanical properties. The results are shown in Table 3.

TABLE 3 CS 1 Ex. 1 Ex. 2 Components in phr YUPLENE ™ BX3900 75 75 75 (phr) ENGAGE ™ 8200 (phr) 25 25 25 Barbituric acid — 0.5 0.2 JetFil ™ 700 (phr) 20 20 20 IRGANOX ™ B 225 0.3 0.3 0.3 (phr) Components in approximate Weight Percent YUPLENE ™ BX3900 62.34 62.09 62.24 (wt %) ENGAGE ™ 8200 (wt %) 20.78 20.70 20.75 Barbituric acid — 0.41 0.16 JetFil ™ 700 (wt %) 16.63 16.55 16.60 IRGANOX ™ B 225 0.25 0.25 0.25 (wt %) Aldehyde VOC Concentrations Formaldehyde (mg/m³) 0.18 ND ND Acetaldehyde (mg/m³) 1.55 ND ND Acrolein (mg/m³) ND ND ND Mechanical Properties Flexural Young's 1783 1720 1706 Modulus (MPa) Flexural Yield Strength 32 31 31 (MPa) Tensile Modulus (MPa) 1800 1750 1720 Tensile Yield Strength 20.9 20.7 20.5 (MPa) Notched IZOD (10P) @ 30.57 23.6 25.7 23° C. (kJ/m²) Notched IZOD (10C) @ 4.95 4.26 4.51 −30° C. (kJ/m²) CS = Comparative Sample. ND = Not Detectable. A sample with an aldehyde content that is not detectable has an aldehyde content that is less than the detection limit of 0.01 mg/m³ (i.e., from 0 mg/m³ to less than 0.01 mg/m³).

4. Results

As shown in Table 3, Inventive Examples 1-2, which are compositions containing (A) polypropylene (YUPLENE™ BX3900), (B) polyolefin elastomer (ENGAGE™ 8200), (C) a compound having the formula (I) (e.g., barbituric acid), (D) a talc additive (JetFi™ 700) and an antioxidant additive (IRGANOX™ B 225) advantageously exhibit reduced aldehyde concentrations compared to CS 1, which lacks a compound having formula (I) and is representative of the state of the art of the automotive industry.

Without wishing to be bound by any particular theory, Applicant believes the compound having formula (I) (e.g., barbituric acid) reacts with aldehydes (e.g., formaldehyde, acetaldehyde, acrolein) present in the composition, which advantageously abates (i.e., reduces) the aldehyde concentration of the composition.

Furthermore, Inventive Examples 1-2 surprisingly and unexpectedly exhibit similar or improved mechanical properties compared to CS 1, indicating Inventive Examples 1-2 are suitable for making articles such as automobile interior parts.

It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as within the scope of the following claims. 

What is claimed is:
 1. A composition comprising: (A) a polypropylene polymer; (B) a polyolefin elastomer; (C) a compound having the formula (I):

wherein R1, R2, and R3 are each independently H, a linear or branched alkyl group having 1 to 10 carbon atoms, a hydroxyl group, a phenyl group, a halogen, —CO2CH3, or —CN; and (D) an additive component.
 2. A composition comprising: (A) from 50 wt % to 85 wt % of a polypropylene polymer; (B) from 5 wt % to 35 wt % of a polyolefin elastomer; (C) from 0.01 wt % to 20 wt % of a compound having the formula (I):

wherein R1, R2, and R3 are each independently H, a linear or branched alkyl group having 1 to 10 carbon atoms, a hydroxyl group, a phenyl group, a halogen, —CO2CH3, or —CN; and (D) from 0 wt % to 30 wt % of an additive component.
 3. The composition of claim 1, wherein the polyolefin elastomer is an ethylene/α-olefin copolymer.
 4. The composition of claim 1 comprising less than 0.01 mg/m³ formaldehyde, as measured in accordance with the VOC Test Method.
 5. The composition of claim 1 comprising less than 0.01 mg/m³ acetaldehyde, as measured in accordance with the VOC Test Method.
 6. The composition of claim 1 comprising less than or equal to 0.01 mg/m³ acrolein, as measured in accordance with the VOC Test Method.
 7. The composition of claim 1 comprising: a flexural modulus and tensile modulus of greater than 1700 MPa; a flexural yield strength of greater than 30 MPa; and a tensile yield strength of greater than 20 MPa.
 8. The composition of claim 1 comprising: an impact strength at 23° C. of greater than 31 kJ/m2; and an impact strength at −30° C. of greater than 4.20 kJ/m2.
 9. An article made from the composition of claim
 1. 10. The article of claim 9 in the form of an automobile interior part. 